ETP Maintenance Training in mg apparel.pptx

ETP training

1. ETP Maintenance Training Prepared By: Karim Bukhsh

2. MAINTENANCE Maintenance can be defined as the act of preserving and keeping the machinery or plant in proper condition by checking & repairing. “A Stitch in time, saves nine”. Maintenance is of two types, Preventive & Corrective . The purpose of maintenance is to preserve and to keep the machinery in a good operating condition. The structures, decking, stairs, handrails should be clean. It is necessary to have PERIODIC MAINTENANCE. Periodic maintenance schedules must be made and CARRIED OUT to have a well-run plant. Good housekeeping is the key to cleanliness, operation, and appearance. Plant is designed to operate at peak efficiency with a minimum amount of maintenance. The maintenance and appearance of plant is indicative of the operations. In general, good maintenance - good appearance means good operations.

3. Preventive Maintenance Corrective Maintenance Preventive Maintenance is type of maintenance in which proper maintenance schedule is set to keep the machine fit an to avoid unexpected failures. Corrective Maintenance is type of maintenance which is done at the spot due to the sudden failure in working of machine. Root cause analysis is done by the “ Team ” to avoid such type of failures in future.

4. Daily Maintenance Checklist Maintenance is a continuous job. In order to be sure that all machines are properly maintained, a check list should be followed . Daily Checklist is as follow: Check all equipment, pumps, motor, overload, circuit breakers, etc., for proper operations. Check Inlet bar screen. Inlet-structure of the pump to be checked for operation. Check sludge line & clean if signs of clogging are observed. Inspect air blower, motor, scooper, and filter. Perform pH and DO tests . Check dosing pumps. Clean your plant Area. Check the dosing tanks repair if leakage is observed Make proper entries in your daily log

5. Weekly Maintenance Checklist Weekly Checklist is as follow: Clean the walls and complete tanks of DAF & DEK to remove any solids so that they will not deposit in tanks. Check oil level in blower timing gear housing. Add or change oil if necessary . “DO NOT OVERFILL” . Clean the DAF & DEK feed pumps. Open up pumps impeller if it is facing any clogging clean it. Electrical panel-control box should be checked for dryness and corrosion.

6. Monthly Maintenance Checklist Monthly checklist is as follow: Check gland packing of all the pumps. Check the belts of blowers. Check the chain of VSGM. Check the electrical load of motors & blowers. Grease all the necessary parts of the plant. Check the oil level in feed pumps, dosing pumps & blowers.

7. Blowers Remove square head oil fill plug on rear end. Remove oil level plug at the end of gear case. Fill gear case until oil drips out of oil level hole. Drain, flush, and refill every 1500 hours. Be sure that the “AIR VENTS” are kept open and clean. Clean the air filters of blowers on daily basis. Bearings on the drive end of the blower require grease lubrication every 500 hours of operation. Bearings which requires grease lubrication will have a grease fitting. To prevent damage to grease seals, add only a small amount of grease and the grease vents must be kept open at all times. Recommended grease ball bearing grease or equivalent. CHANGE OR ADD OIL WHEN NEEDED CAUTION: DO NOT OVER – LUBRICATE

8. Possible Problems Problem Possible Cause Solution       Feed Pumps NRV Clogging   Priming   Impeller Clogging   Coupling   Electrical Problem Open the suction line to clean NRV   Do Priming   Open the impeller of pump and clean it   Replace coupling with new one   Call electrical team     Pump Vibrating Pump frame looseness   Pump bolts looseness   Pump alignment   Tight the bolts of pump frame   Tight the bolts of the pump   Properly align the pump and motor shaft with help of maintenance team     Chemical Dosing Problem Clogging in dosing line   NRV issue   Pump electrical problem Properly mix chemicals Check & clean NRV of dosing lines   Call electrical team       Motor & Blowers Power Failure   Bearing Issue   Belt Issue   Pulley   Oil & Greasing     Call electrical team   Check & replace with new one if necessary Check & replace with new one if necessary Call maintenance team   Change oil properly and grease all the parts where necessary

9. Any Question?